This document establishes standardized packaging and palletization requirements for specialized product categories at Costco Wholesale, ensuring consistent load stability, product protection, and operational safety across the entire supply chain—from warehouse distribution centers to in-store sales floors. These guidelines are designed to address unique handling challenges for long-handled tools, soft bulk goods, and fragile flat items (e.g., mirrors, framed art), mitigating risks of product damage, load tipping, and workplace incidents during transit, storage, and display. Adherence to these specifications is critical to maintaining Costco’s reputation for quality, efficiency, and customer safety, while aligning with global logistics and retail operations standards.

1. Master Display Requirements (For Long-Handled Tools: Mops, Brooms, Pruners, Shovels)

Container & Material Specs

- Base Structure: Regular Slotted Container (RSC) with 2.25"/5.7 cm rollover top flaps, equipped with pop-in tray supports at all four corners.

- Board Standard: Minimum 44 ECT/275 lb. Mullen test board, C flute construction; double-wall board is recommended for heavier items like pruners and shovels.

- Tray Design: Two corner-cut trays with die-cut holes on both top and bottom layers to ensure vertical pole stability during transit.

Stability & Security

- Each master display unit must be banded to its pallet to prevent tipping during transit or on the sales floor.

- A corrugated shroud may be required for additional stability and product protection during handling and shipping.

2. Bulk Bin Requirements (For Soft Goods: Pet Beds, Throws, Pillows)

Material & Structure

- Board Standard: Minimum 44 ECT/275 lb. Mullen test board, C flute construction; double-wall board is recommended.

- Dimensions: Bulk bins must feature a 48"/121.9 cm front side and two 40"/101.6 cm side panels. Tear panels are prohibited.

- Front Opening: U-shaped cutouts on the front panel must not exceed 50% of the panel height, with full-depth rollovers to enhance structural strength.

Reinforcement & Enclosure

- Inner triangular corner supports must be fastened or adhered to all four inside corners.

- A corrugated shroud and deep-skirt pallet cap are required to fully enclose the unit load.

- Corner posts and two belly bands are recommended for extra rigidity.

3. Wood Pallet Side-Load Crate Requirements (For Fragile Flat Items: Large Mirrors, Framed Art)

Crate & Pallet Specs

- Crate Structure: Products must ship in a wood crate with dividers or plastic runners (top and bottom) to separate and secure items.

- Pallet Compatibility: Wood crates must attach to a 48" x 40"/121.9 cm x 101.6 cm wood pallet that adheres to Costco’s official wood pallet specifications (refer to Pallet Specifications reference pages).

Labeling & Accessibility

- A header label is required to display product assortment; each item must have a photo sticker or illustration on the spine for clear identification.

- Each item must include a plastic strap handle or reinforced hand cutout to enable easy sliding in/out of the crate.

General Compliance Notes

All configurations must prioritize load stability, product protection, and warehouse/sales floor safety. Deviations from these guidelines require prior approval from Costco’s logistics and packaging teams.